E3T E3T E nergy E fficiency E merging T echnologies Microwave - - PowerPoint PPT Presentation

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E3T E3T E nergy E fficiency E merging T echnologies Microwave - - PowerPoint PPT Presentation

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E3T E3T E nergy E fficiency E merging T echnologies Microwave Assisted Thermal Sterilization - MATS Emerging Technologies Showcase January 21, 2015 Bill Wilson, P.E. Washington State University Extension Energy Program 1 GoToWebinar

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E3T E3T

Energy Efficiency Emerging Technologies

Microwave Assisted Thermal Sterilization - MATS™

Emerging Technologies Showcase

January 21, 2015 Bill Wilson, P.E. Washington State University Extension Energy Program

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Introduction

What we are going to discuss:

New process technology for post-packaging processing (sterilization) of low-acid/high-moisture food products resulting in long-term, ambient condition, shelf-stable, food products preservation

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BPA TI Project Funding Acknowledgement

http://www.bpa.gov/Doing%20Business/TechnologyInnovation/TIPProjectBriefs/2014-TIP-261.pdf

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Microwave Assisted Thermal Sterilization (MATS™)

  • Developed by Dr. Juming Tang’s Microwave Group at Washington

State University, Pullman Campus – affiliated with the Department of Biological Systems Engineering

  • Adaptation of 915 MHz frequency microwave energy for internal

heating of food products in their hermetically sealed storage containers to sterilization temperatures

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  • Process for deactivation of microorganisms and their spores.

Internal temperatures in excess of 212oF required (generally 250 – 265oF), with adequate “holding” time once temperature is reached

  • We are all very familiar with conventional post –packaged

sterilization technologies as food processors, domestic food preservationists, or consumers

  • Examples of products created using conventional technologies and

target categories for MATS™ technology follow ….

What is Post-Packaging Sterilization?

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Examples of Post-Packaged Sterilized Products

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How is Post Packaging Thermal Sterilization Achieved?

  • Imparting thermal energy to heat container and

contents to sterilization temperature

  • For flexible or semi-rigid non-metallic containers

in particular must be done in pressurized atmosphere environment to avoid product water content vaporization

  • Most frequently, pressurized atmosphere is steam

(15 psig sat. steam ~247oF), or hot water at sterilization temperature maintained at 20 psig or greater pressure

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Attributes of MATS™ vs. Conventional Technologies

  • Benefits
  • Significant reduction in thermal processing time (1/4 to 1/10 of conventional

processing time)

  • Greatly improved product visual and sensory appeal - particularly prepared meals

containing delicate ingredients

  • Improved nutrient retention
  • Inherently capable of adaptation to continuous-type sequential processing system

design

  • Shelf-stable end-products eliminate refrigeration requirements for processing,

warehousing, transportation, retail sales storage/presentation

  • Initial indication of a reduction in processing energy intensity (gross combined

process energy consumption/unit mass of product) – usually stated as Btu’s per lb.

  • f product
  • Drawbacks
  • Processing energy cost/production unit increase due to electrical vs. thermal

energy utilization (particularly for natural gas)

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Conventional Sterilization Methods

  • Conventional Technologies
  • Steam heated retorts (also called “autoclaves”)
  • Water immersion retorts
  • Steam water spray retorts
  • All types –
  • Batch operation (most typical)
  • Continuous operation (rare)
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Disadvantages  Warm-up losses  Vent & bleeder losses  Product thermal mass  Long come-up & cook time  Long product cooling time

Batch-Type Retorts – “Still” Steam

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Batch-Type Retorts – Water Immersion (with Water Recovery Vessel)

Disadvantages  Warm-up losses  Long come-up & cook time  Long product cooling time

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Batch-Type Retorts – (Steam Water Spray)

Disadvantages  Warm-up losses  Electrical & Compressed Air Consumption Advantages  No Steam Venting Loss  No Continuous Bleeder Loss  Minimal Water Volume Heat-up

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WSU MATS™ 40 kW Pilot Line

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WSU MATS™ Semi-Continuous 40 kW Pilot Line

View: Preheating Section (lower) Microwave Section (Upper) 20 KW 915 MHz Microwave Generators

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Summary of WSU MATS™ Major Milestones

July 2001 Formed WSU Microwave Consortium I July 2001 Developed first 915 MHz single mode pilot system (10 kW)

  • Oct. 2006

Received US patent for 915 MHz single mode microwave sterilization system design

  • Aug. 2007

Developed a second generation system semi-continuous system (40 kW)

  • Oct. 2009

Received FDA acceptance for MW sterilization of mashed potato in 10 oz. trays

  • Nov. 2010

Formed MW Consortium II, focusing on commercialization

  • Nov. 2010

Food Chain Safety (Maple, Valley, WA) is granted license for exclusive rights for commercialization of MATS™ Technology [Now 915 Labs]

  • Dec. 2010

Received FDA acceptance for MW sterilization of salmon fillets in sauce in 8 oz. pouches

  • Mar. 2012

Received non-objection letters from USDA FSIS

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Retort Processes Energy Consumption Comparisons

  • Like many Energy Consumption

Comparisons – “It Depends”

  • Currently batch or continuous
  • peration?
  • Product temperature increase required
  • Equipment capacity utilization and

density of product pack

  • Initial projection of Microwave compared

with batch processing indicates favorable energy intensity and overall energy efficiency metrics

Energy Intensity??

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Commercial Assessment Outcome Summary

7.1 10.4 32.5 5 10 15 20 25 30 35 Still Steam Immersion w/ Water Recovery Steam Water Spray Lb/Ft3

  • Lb. Product/Ft3 Usable Retort Volume

(As Measured/Estimated)

Product/Volume Ratio 864 1,293 300 260 200 400 600 800 1,000 1,200 1,400 Still Steam Immersion w/ Water Recovery Steam Water Spray Continuous Rotary Retort (cans) Energy Intensity, Btu/lb Product

Energy Intensity (As Measured/Estimated)

Energy Intensity

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Commercial Assessment Outcome Summary

651 1293 658 260 200 400 600 800 1,000 1,200 1,400 Still Steam Immersion w/ Water Recovery Steam Water Spray Continuous Rotary Retort (cans) Energy Intensity, Btu/lb Product

Energy Intensity Normalized for Pack Density & Temp. Rise

Energy Intensity

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Input Energy Distribution

29.0% 18% 56.2% 79.2% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Still Steam Horizontal Water Immersion Steam Water Spray Continuous Rotary Retort (cans)

Input Energy Distribution (As Measured/Estimated)

Electrical Product & Container Sensible Heat: Surface Losses Preheating Bleeder Losses Vent Losses

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WSU Microwave Group: www.microwaveheating.wsu.edu Food Chain Safety/915 Labs: www.fcsmats.com Bill Wilson: wilsonb@energy.wsu.edu

(360) 956-2041

For Additional Information:

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Thank you for attending

Information and registration at www.e3tnw.org/webinars Join our email list for notification of future webinars at subscribe-e3tnw@listserv.energy.wsu.edu More information about emerging technologies:

E3T database: www.e3tnw.org E3T Program: www.bpa.gov/energy/n/emerging_technology/ Conduit: www.ConduitNW.org

Thank you for attending our E3T Showcase Webinar!